EV Charger Commissioning Checklist: Tests Before Handover

Short answer: commissioning has five parts — inspect, test electrically, connect, configure, charge a real car — and ends with a signed record. Skipping the real-car test or the back-end check is the most common reason a “finished” charger fails in its first week.

Checklist

1. Visual inspection (before power)

• Charger model and rating match the order and the design
• Mounting secure; plinth or wall suitable; no damage in transit
• Cable entries sealed; glands tight; IP rating intact
• Cable size and protective devices match the design — see wire size
• SPD installed where required — see surge protection
• Labels in place: circuit identification, warnings, emergency contact

2. Electrical tests (before energising the charger)

Test	Pass criterion	Record
Continuity of protective conductors	Low resistance on the earth path	Value
Insulation resistance	Meets the code limit (commonly ≥ 1 MΩ at 500 V)	Value per conductor pair
Polarity and phase rotation	Correct	Pass/fail
Earth loop impedance (TN) or electrode resistance (TT)	Below the limit for the protective device	Value — see earthing
RCD trip current and time	Trips within the standard’s limit	Time and current
Supply voltage and frequency	Within the charger’s range	Values

3. Energise and check the charger

• Display, LEDs and start-up self-test OK
• Supply voltage on all phases correct under load
• Protective earth detection OK
• Emergency stop and door switch work (DC)
• Insulation monitoring works (DC)
• Charger time and date correct

4. Communication and settings

• Network link (Ethernet, Wi-Fi or 4G) connected with good signal — see connectivity
• Charger connects to the back end; ID matches
• OCPP version and security profile set — see cybersecurity
• Maximum current and load management set
• Authentication (RFID, app, plug & charge) works
• Tariff, meter values and sessions arrive at the back end
• Remote start, stop and reset work
• Firmware version recorded; update process confirmed — see OTA updates

5. Test charge

• At least one real vehicle per connector, charging for 10–15 minutes at full power
• For DC: a second vehicle model if available
• Current, power and energy readings are plausible
• Charger stops cleanly; cable releases; session recorded
• Temperatures stable; no unusual noise or smell

6. Handover

• Installation certificate and test results signed
• Settings exported or recorded; passwords handed to the owner
• Owner trained: starting a session, error indicators, emergency stop
• Support contact and warranty documents given
• Photos of the finished installation and the inside of the charger

Common failures found at commissioning

1. No communication because the 4G module has no signal or the Wi-Fi password is wrong.
2. Wrong current limit left at the factory default.
3. Earth fault from a loose conductor.
4. Vehicle compatibility — rare, but a particular car refuses to start; real-car tests find it before the customer does.
5. Phase sequence or neutral wrongly connected on a three-phase charger.

DC specifics

A DC charger needs a longer test: the power modules are checked under load, insulation monitoring is tested, cable cooling is checked at high current, and the charger is tested with vehicles of different voltage classes. See DC charger installation.

VULTAE support

VULTAE supplies installation manuals with every model; ask us about commissioning support for your project. Use the checklist above together with the installation requirements guide, and keep the results for the warranty — see warranty and service.